Variable wall structure

ABSTRACT

A variable wall structure in which a wall is formed by a plurality of overlying horizontal courses of building blocks, with adjacent building blocks in the same course being spaced from one another to provide openings in the wall, and with the openings in adjacent courses of blocks being staggered with respect to each other. Vertical alignment channels formed in the blocks and alignment wedges are placed in the channels to assure proper alignment of the blocks in successive courses of blocks. The blocks define circular vertical openings and expandable sleeves are inserted in the openings. Mortar is poured down the aligned openings and sleeves to bond the blocks of the wall structure. Filler blocks are provided to be received within the wall openings, and means are provided to hold the filler blocks in place prior to application of a grout or other holding means. The filler blocks can be selectively positioned to give the finished wall any of a number of desired appearances.

llnited States Patent Muse 45] Sept. 26, 1972 154] VARIABLE WALL STRUCTURE 3,479,782 11/1969 Muse ..52/438 72' Inventor: George B Muse, Calhoun Ga. 2,684,588 7/1954 Robertson ..52/585 30701 FOREIGN PATENTS OR APPLICATIONS 1 1 Filed: 2 1 7 182,348 6/1955 Australia ..46/26 999,177 1/1952 France ..52/438 [2]] Appl' 83939 354,307 11/1937 Italy ..52/585 Related Us, Applicafion Dam 238,908 3/1965 Austria ..52/79 653,710 7/1963 ltaly ..52/585 [631 cmlmuaton-m-pm 26,764 5/1902 Switzerland ..52/585 Primary Examiner-Frank L. Abbott [52] US. Cl. ..52/438, 52/585, 52/604, Assistant Examiner Les|ie Braun 52lDIG- 2 Attorney.lones & Thomas [51] Int. Cl ..E04b 2/46, E04c 1/08, E04c 1/10 [58] Field of Search...52/604, DIG. 2, 438, 303, 306, 57 ABSTRACT 52,507 46/26 A variable wall structure in which a wall is formed by a luralit of overl in horizontal courses of buildin [56] References (med bl cks, 31th ad ac em building blocks in the Sam: UNITED STATES PATENTS course being spaced from one another to provide openings in the wall, and with the openings in adjacent MUSC 4 courses of blocks Staggered respect to each other Vertical alignment channels formed in the et al blocks and alignment wedges are placed in the han- Underwood nels to assure proper alignment of the blocks in ue- 2,141,397 12/1938 Locke ..52/506 cessive courses of blocks, The blocks define circular 1,950,397 3/1934 Cahill ..52/303 vertical openings and expandable Sleeves are inserted 2,498,276 2/1950 Kany ..52/438 in the openings. Mortar is poured down the aligned 1,976,858 10/1934 Ritter ..52/302 openings and sleeves to bond the blocks of the wall 2,708,329 5/1955 McKee ..52/593 structure. Filler blocks are provided to be received 738,643 9/1903 Van Camp ..52/303 within the wall openings, and means are rovided to 2,236,926 4/1941 Surface ..52/585 hold the filler 9 Place P110 aPP canon of a 1 296 342 3/1919 Tozzi ..52/585 grout other P' f 9" blocks can be selectively positloned to give the finished wall any of a 1,216,550 2/1917 DeCicllani ..52/503 b fdesired a earances 1,444,554 2/1923 Quillet ..52/585 em pp MCCluSkey 3 Claims, 6 Drawing Figures 3,036,407 5/1962 Dixon ..52/585 PATENTE8sEP2s I972 sum 1 or z INVENTOR GEORGE B. MUSE gawm Y ATTORNEYS PATENTEI] SEP 2 6 I972 SHEET 2 OF 2 VARIABLE WALL STRUCTURE CROSS REFERENCE TO RELATED APPLICATION This application is a continuation-in-part of the copending application for WALL STRUCTURES filed Jan. 2, 1970, under Ser. No. 252.

BACKGROUND OF THE INVENTION In the past, when a block wall was to be constructed with varying designs appearing in the wall surface, the builder or designer of the wall usually constructed the wall on a progressive basis by placing the design blocks in the wall with the building blocks as the wall was built. This was necessary because of the design blocks of the wall were usually required as a structural component of the wall to help support the surrounding portions of the wall. In a block wall structure where the building blocks are long enough and can be spaced apart so that apertures can be formed in the wall and the design of the wall placed in the openings after the wall has been formed, the builder of the wall is handicapped by the fact that the openings in the wall usually are not formed of uniform size and shape, and the design blocks to be placed in the openings usually will not fit all the openings. Moreover, the typical apertured wall structure is inherently week and unsuitable for most structural purposes.

In addition to these structural and functions shortcomings, structural the builder of a wall which included design blocks which was to. be progressively built was forced to have at hand both the plain blocks and the various different design blocks which were to form the design of the wall, and once a design block was laid, it was onerous to remove the design block to alter the design of the wall.

SUMMARY OF THE INVENTION The present invention provides apparatus for forming wall structures of various designs and includes a building block that is adapted to be used to build a basic wall structure having uniformly sized and dispersed openings therein. Vertical circular openings are formed in the end one-fourth portions of the blocks and expandable sleeves are inserted in the openings as the blocks are laid. The sleeves extend between adjacent courses of blocks and function to space the blocks apart in each course of blocks to form the openings in the wall structure which are uniformly sized and spaced. Vertical alignment channels are formed in the blocks and wedges are placed in the alignment channels at the junction between the blocks of adjacent courses of blocks to assure proper vertical alignment of each block with the two blocks that overlie the block above and below the block. The openings of the wall structure and the alignment channels of the building blocks are arranged so that, after the apertured wall has been constructed, alignment wedges can be inserted into the alignment channels. After the basic apertured wall structure has been constructed, filler blocks are inserted into the openings within the apertured wall. The filler blocks provide both a closure means for openings in the wall as well as the esthetic design for the wall. Means are provided for holding the filler blocks into position until grout or other sealing means is applied about the filler blocks to render the wall a unitary construction. Mortar can be poured down the aligned vertical circular openings in the blocks and expandable sleeves to lock the building blocks together either before or after the filler blocks have been inserted in the openings of the wall structure.

BRIEF DESCRIPTION OF THE DRAWING FIG. 1 is a perspective view of a portion of a block wall constructed in accordance with the present invention;

FIG. 2 is an enlarged perspective view showing the details of construction of the wall shown in FIG. 1;

FIG. 3 is an explodedperspective view showing the junction of two building blocks;

FIG. 4 is a vertical cross-sectional view substantially through the centerline of one of the filler blocks, taken along lines 44 of FIG. 2.

FIG. 5 is a perspective view of an alignment wedge; and,

FIG. 6 is a perspective view of a retainer clip for use with the filler block.

DESCRIPTION OF A PREFERRED EMBODIMENT Referring now more particularly to the drawings, and to that particular embodiment here chosen by way of illustration, it will be seen in FIG. 1 that the wall structure 9 comprises two kinds of blocks, viz., a building block 10 and a design or filler block 11. The building blocks 10 are laid in successive, parallel, horizontal courses with the end portions of the building blocks 10 overlying each other in successive courses. This arrangement leaves a space 12 between each block in each course of the wall, and it is into the space 12 that the filler block 11 fits. The filler block 11 is designed to fill the space 12 to make a complete, solid wall.

Referring now primarily to FIG. 2 in the drawings, it will be seen that the building block 10 has a back 14, a front face 15, right and left end surfaces 16 and 18 respectively, and top and bottom surfaces 19 and 20 respectively.

Centrally positioned in each end one-fourth portion of each block 10 there is a circular opening 21 and 22 which extends from the upper surface 19 to the bottom surface 20. These openings 21 and 22 are here shown as circular and of uniform diameter along their lengths, but it will be understood that other shapes might be used, the purpose being simply to provide a continuous opening throughout the height of the wall as will be seen hereinafter.

Expandable sleeves or tubular members are placed in the openings 21 and 22 for alignment and connecting purposes. Sleeves 60 can be fabricated of various materials including plastic, metal, etc but are preferably of a material having a resistance to shear and one that is resilient. Sleeves 60 can be of various shapes and sizes but preferably are cylindrical and expandable by means of open ended slot 61. As the blocks are assembled as illustrated in the drawing, sleeves 60 which are of a height less than the height of the blocks are inserted into the circular openings 21 and 22 of the lower blocks so that they protrude up from the openings, and the openings of the upper blocks are then fit down onto the sleeves. This accurately positions the blocks in the wall structure. Subsequently mortar or other cementitious substance 62 can be poured down the aligned openings and sleeves. The mortar further urges the sleeves into engagement with the inside surfaces of the openings 21 and 22 which further assures exact alignment of the blocks, and when the mortar dries the blocks will be rigidly bonded together. The substantially incompressible cured mortar surrounded by the substantially unshearable sleeve form an unexpectedly strong connection between the blocks.

The block also has a vertically disposed central opening 24. As is conventional in concrete blocks, the opening 24 is provided to reduce the amount of material in the block to provide a lighter weight block and to provide an air gap for heat and moisture insulation; however, the central opening 24 in the present block is of a particular configuration to contribute to the alignment of vertically disposed blocks. It will be seen from the drawings that the opening 24 defines internal alignment channels 25 and 26, the channels 25 and 26 being parallel to each other, coextensive with the central opening 24 and adjacent to the face of the block 10.

Each of the ends 16 and 18 of block 10 has an external alignment channel 28 and 29 respectively, the channels 28 and 29 being similar in size and shape to internal channels and 26. External channels 28 and 29 are spaced from the face 15 of the block 10 the same distance as internal channels 25 and 26, and external channels 28 and 29 extend inwardly of the block from the end walls 16 or 18 the same distance as internal channels 25 and 26 extend into the block from the central opening 24.

The block 10 is so proportioned that the opening 22 in the block 10 can be placed directly above the opening 21 in another block, and the end wall 16 of the block 10 will be substantially aligned with one end of the central opening 24 in the contiguous block. Because of the particular arrangement of the channels 25, 26, 28 and 29 external channel 28 in the upper block will then be aligned with internal channel 26 in the lower block and external channel 25 in the upper block will be aligned with internal channel 29 in the lower block. This relationship is shown in FIG. 2 in which a block is shown in the phantom lines and it will be seen that the opening 22 of the upper block is directly aligned with the opening 21 in the lower block, and the end wall 16 of the upper block is directly aligned withone end of central opening 24 in the lower block. The external channel 28 in the upper block is then aligned with internal channel 26 in the lower block, and internal channel 25 in the upper block is aligned with external channel 29 in the lower block. It will also be seen from-this description that, after several of the blocks 10 have been placed together as described, the spacebetween the adjacent blocks allows access to the junction of all of the channels 25, 26,

Referring primarily to FIGS. 2 and 4 of the drawings, it will be seen that a filler block 11 is provided, the tiller block 11 being adapted to be received within the openings 12 in the apertured wall 9.

Each filler block includes right and left sides 30 and 31 respectively, front and rear faces 32 and 34 respectively, and top and bottom surfaces 35 and 36 respectively. The front face 32 is the decorative face of the filler block and would have some form of decoration thereon, though it will be understood that a completely flat surface would, in the present invention, be considered a decorative surface.

The top surface 35 of the filler block 1 1 has therein a notch or groove 38, the notch 38 being substantially in the center of the upper surface 35 of the filler block 1 l and extending from the rear surface 34 into the block 11, but not meeting the front surface 32 of the block 1 1.

Referring now to FIG. 5 in the drawings, it will be seen that wedge members such as alignment wedges 40 are provided, the alignment wedges 40 being preferably of a somewhat elastic sheet material, a resilient metal such as spring steel, or of plastic. The alignment wedges 40 have two legs 41 and 42 joined by a return bend 44. Each of the legs 41 and 42 has an inwardly angled portion 45 and 46 respectively. The degree of the angle of the angled portions 45 and 46 is such that, when the legs 41 and 42 of an alignment wedge 40 are urged towards each other, the tip ends of the legs 41 and 42 will abut, and the main portions of the legs 41 and 42 will then be parallel to each other.

Looking at FIG. 6 of the drawings, there is shown a retaining clip 50 which has two legs 51 and 52 joined by a return bend 54. The retaining clip 50 is also formed of resilient sheet material.

From the above discussion, it should now be understood that when it is desired to construct a wall 9 in accordance with the present invention the building blocks 10 are first laid in successive courses with the end openings 21 and 22 aligned with one another with sleeves inserted in the openings and assuring proper alignment and a series of vertical openings are formed at spaced intervals throughout the height of the wall structure. Internal alignment channels 25 and external alignment channels 28 will be substantially aligned with one another and internal alignment channels 26 and external alignment channels 29 will be substantially aligned throughout the height of the wall.

Through each of the openings in the wall constructed by the building blocks 10, a person can reach each of the junctions of the alignment channels and place one of the alignment wedges 40'into the junction of the alignment channels. When each alignment wedge 40 is depressed so that the tip ends of the legs 41 and 43 abut, the remaining width of the alignment wedge 40 will be approximately equal to the width of the alignment channels 25, 26, 28 and 29, so the alignment wedge 40 will remain in place at the junction of the alignment channels. The alignment wedges urge the flat sides of the alignment channels into alignment so that the blocks are more perfectly aligned. While the sleeves 60 perform a spacing and aligning function, the sleeves are of larger diameter and the strength of the sleeves is not as great as the alignment wedges, particularly because of the smaller size of the alignment wedges and because of the abutting ends of the alignment wedges. The abutting ends of the alignment wedges greatly increase the resistance of compression of the wedges, so that the wedges securely connect the blocks together in precise alignment.

At this point, an inspection can be made of the wall to check the construction to be sure that the alignment wedges 40 have been placed at all of the junctions of the alignment channels. To facilitate this inspection, it will be obvious that the alignment wedges can be provided in a distinctly contrasting color so that they will be readily visible to an inspector by looking into the openings of the wall structure.

After the apertured wall structure has been constructed of the construction blocks 10, the filler blocks 11 can be put into place. Due to the size of the tiller block 11 with respect to the openings in the apertured block wall, the filler block 11 will fit quite snugly into the openings in the block wall. As best shown in FIG. 4 of the drawings, it will be seen that a retaining clip 50 is first placed into the slot 38 of the filler block 11 with the return bend 54 of the retaining clip 50 pointed towards the wall. The filler block 11 can now be slid into the openings, and the retaining clip 50 will bend to allow easy entry of the filler block 11 into the openings of the wall. Once the filler block is within the opening in the wall, the retaining clip 50, due to its spring bias, will urge the leg 51 upwardly so that the tip of the leg 51 tends to bite into the building block to prevent removal of the filler block 11.

It will be understood that when the wall has been constructed as above described, the wall will have exceptionally good rigidity and precise alignment so that a wall of considerable size can be constructed in the manner described without the use of any additional supports, mortar or other form of grout.

After the wall has been completely constructed and all adjustments asto the placement of the design blocks have been made so as to have the desired appearance, the aligned openings 21 and 22 in the construction blocks and expandable sleeves 60 inserted therein can be filled with mortar or some other form of material that would tend to rigidify the wall; also grout can be placed in the seams about the design blocks and the face of the wall can be coated with a material that will both seal and further rigidify the wall, if desired.

It will of course be understood by those skilled in the art that the particular embodiment of the invention here chosen by way of illustration is meant to be in no way restrictive; therefore, numerous changes and modifications may be made and the full use of equivalents resorted to without departing from the scope of the invention as defined in the appended claims.

lclaim:

l. A block wall formed by a plurality of building blocks arranged in parallel courses, the building blocks in each course being spaced from one another to form apertures, the building blocks in successive courses being staggered so that each building block partially overlies two other building blocks, each of the said building blocks having a central opening therethrough partially defined by a pair of sides, a plurality of alignment channels defined in said building block, all of said alignment channels being parallel to one another, with ones of said alignment channels being defined in each end of the said building block and ones of said alignment channels opening into each of said sides of the said central opening, all of the said alignment channels being the same distance from the front face of the building block, each of said building blocks being of such length that one of said alignment channels in an end of one building block is disposed in junction to be continuous with one of the said alignment channels opening into one of the sides of said central opening of a contiguous block, and a plurality of filler blocks each received within one of the said apertures, said filler blocks including a top surface having a notch therein, and a retainer clip within the said notch, said retainer clip having a first portion resiliently biased against said filler block and a second portion resiliently biased away from said first member and into retaining contact with a surface of an adjacent one of said building blocks, said filler blocks further having a decorative face protruding from one side of the said block wall.

2. A block wall formed by a plurality of building blocks arranged in parallel courses, the building blocks in each course being spaced from one another to form apertures, the building blocks in successive courses being staggered so that each building block partially overlies two other building blocks, each of the said building blocks having a central opening therethrough partially defined by a pair of sides, a plurality of alignment channels defined in each of said building blocks, all of said alignment channels being parallel to one another, one of said alignment channels being defined in each end of the said building block and ones of said alignment channels opening into each of said sides of the said central opening, all of the said alignment channels being the same distance from the front face of the building block, each of said building blocks being of such length that one of said alignment channels in an end of one building block is disposed in junction to be continuous with one of the said alignment channels opening into one of the sides of said central opening of a contiguous block, a plurality of filler blocks each received within one of the said apertures, and wedge members received within the junctions of alignment channels, said wedge members each including a pair of outwardly biased leg members which are normally spaced apart farther than the width of said alignment channels and stop means disposed to limit the inward movement of said leg members to an extent which prevents the spacing of said leg members from becoming substantially less than the width of said alignment channel.

3. A wall structure comprising a plurality of substantially identical rectangular building blocks each having generally planar end wall and top and bottom wall surfaces and substantially impervious planar side wall surfaces, with the length of each block being approximately four times its width, said blocks each defining a substantially vertical generally circular opening extending therethrough from its top wall to its bottom wall surfaces centrally in each end one-fourth portion thereof, said blocks being arranged in a series of horizontal courses of blocks with each block in each course of blocks being spaced from the next adjacent blocks in its course and having its top wall and bottom wall surfaces overlying and in abutment with the next adjacent blocks in the courses of blocks next above and next below by approximately one-fourth of its length at each of its ends and with the circular openings in each end one-fourth portion thereof being in alignment with the circular openings of its overlying blocks, resilient radially expandable tubular sleeves each defining a slot from end-to-end and expandable from a size smaller than the circular openings in the end one-fourth portions of each block to a size larger than the circular openings in the end one-fourth portions of each block positioned internally of said wall structure in at least some of said circular openings and extending between adjacent courses of blocks and radially expanded outwardly into frictional engagement with the surfaces of said openings, columns of solidified cementitious substance at least partially filling some of said tubular inserts and locking said tubular inserts in outwardly expanded positions against the surfaces of the circular openings of said blocks, the openings in the wall structure between the blocks in each course of blocks being substantially equal in size and shape and substantially equally spaced along the length of each course of blocks, and wall opening filler blocks positioned in at least some of said wall openings defined between the blocks in each course of blocks, said wall opening filler blocks being sized and shaped to substantially fill said wall openings, each of said building blocks defining a central opening therein extending from its top wall to its bottom wall, an alignment channel defined in each end wall and a pair of alignment channels defined internally of the building block and communicating with said central opening, all of said alignment channels being parallel to one another and equally spaced from the side wall surfaces of the building block and positioned in alignment with the alignment channels of overlying building blocks in the wall structure, and wedge members inserted into aligned ones of the alignment channels of abutting overlying blocks. 

1. A block wall formed by a plurality of building blocks arranged in parallel courses, the building blocks in each course being spaced from one another to form apertures, the building blocks in successive courses being staggered so that each building block partially overlies two other building blocks, each of the said building blocks having a central opening therethrough partially defined by a pair of sides, a plurality of alignment channels defined in said building block, all of said alignment channels being parallel to one another, with ones of said alignment channels being defined in each end of the said building block and ones of said alignment channels opening into each of said sides of the said central opening, all of the said alignment channels being the same distance from the front face of the building block, each of said building blocks being of such length that one of said alignment channels in an end of one building block is disposed in junction to be continuous with one of the said alignment channels opening into one of the sides of said central opening of a contiguous block, and a plurality of filler blocks each received within one of the said apertures, said filler blocks including a top surface having a notch therein, and a retainer clip within the said notch, said retainer clip having a first portion resiliently biased against said filler block and a second portion resiliently biased away from said first member and into retaining contact with a surface of an adjacent one of said building blocks, said filler blocks further having a decorative face protruding from one side of the said block wall.
 2. A block wall formed by a plurality of building blocks arranged in parallel courses, the building blocks in each course being spaced from one another to form apertures, the building blocks in successive courses being staggered so that each building block partially overlies two other building blocks, each of the said building blocks having a central opening therethrough partially defined by a pair of sides, a plurality of alignment channels defined in each of said building blocks, all of said alignment channels being parallel to one another, one of said alignment channels being defined in each end of the said building block and ones of said alignment channels opening into each of said sides of the said central opening, all of the said alignment channels being the same distance from the front face of the building block, each of said building blocks being of such length that one of said alignment channels in an end of one building block is disposed in junction to be continuous with one of the said alignment channels opening into one of the sides of said central opening of a contiguous block, a plurality of filler blocks each received within one of the said apertures, and wedge members received within the junctions of alignment channels, said wedge members each including a pair of outwardly biased leg members which are normally spaced apart farther than the width of said alignment channels and stop means disposed to limit the inward movement of said leg members to an extent which prevents the spacing of said leg members from becoming substantially less than the width of said alignment channel.
 3. A wall structure comprising a plurality of substantially identical rectangular building blocks each having generally planar end wall and top and bottom wall surfaces and substantially impervious planar side wall surfaces, with the length of each block being approximately four times its width, said blocks each defining a substantially vertical generally circular opening extending therethrough from its top wall to its bottom wall surfaces centrally in each end one-fourth portion thereof, said blocks being arranged in a series of horizontal courses of blocks with each block in each course of blocks being spaced from the next adjacent blocks in its course and having its top wall and bottom wall surfaces overlying and in abutment with the next adjacent blocks in the courses of blocks next above and next below by approximately one-fourth of its length at each of its ends and with the circular openings in each end one-fourth portion thereof being in alignment with the circular openings of its overlying blocks, resilient radially expandable tubular sleeves each defining a slot from end-to-end and expandable from a size smaller than the circular openings in the end one-fourth portions of each block to a size larger than the circular openings in the end one-fourth portions of each block positioned internally of said wall structure in at least some of said circular openings and extending between adjacent courses of blocks and radially expanded outwardly into frictional engagement with the surfaces of said openings, columns of solidified cementitious substance at least partially filling some of said tubular inserts and locking said tubular inserts in outwardly expanded positions against the surfaces of the circular openings of said blocks, the openings in the wall structure between the blocks in each course of blocks being substantially equal in size and shape and substantially equally spaced along the length of each course of blocks, and wall opening filler blocks positioned in at least some of said wall openings defined between the blocks in each course of blocks, said wall opening filler blocks being sized and shaped to substantially fill said wall openings, each of said building blocks defining a central opening therein extending from its top wall to its bottom wall, an alignment channel defined in each end wall and a pair of alignment channels defined internally of the building block and communicating with said central opening, all of said alignment channels being parallel to one another and equally spaced from the side wall surfaces of the building block and positioned in alignment with the alignment channels of overlying building blocks in the wall structure, and wedge members inserted into aligned ones of the alignment channels of abuttiNg overlying blocks. 